Modular half door

ABSTRACT

A side door assembly is provided for an automotive vehicle body having a side opening. The side door assembly includes a front casting for hinged connection to the vehicle body. A rear casting is also provided for latch connection of the vehicle door assembly to the vehicle. An extrusion and/or extrusions connect the front and rear castings providing a side door assembly that is extremely light, enhancing the ability of the driver to enjoy the vehicle.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/468,666, filed Mar. 8, 2017 and U.S. Provisional Application No. 62/640,317, filed Mar. 8, 2018. The disclosures of the above applications are incorporated herein by reference.

FIELD OF THE INVENTION

The field of the present invention is that of side doors for automotive vehicles, more particularly, side doors for sport utility vehicles such as those manufactured by Jeep and that are customizable by the owner.

BACKGROUND OF THE INVENTION

Many owners of sport utility vehicles, especially Jeeps, seek to enjoy their vehicles in the outdoors. To maximize the outdoor experience, many owners replace their original equipment side doors for other side doors that can be customized to enhance the driving experience. Often these doors allow the car operator to have greater exposure to the outdoor environment. It is desirable that these customizable doors be as rigid as possible to minimize squeaks and rattles while at the same time being as light as possible to maximize the joy of driving such a vehicle.

SUMMARY OF THE INVENTION

To make manifest the above noted and other gainful desires, a revelation of the present invention is brought forth. In a preferred embodiment the present inventions endows the freedom of a side door assembly for an automotive vehicle body having a side opening. The door assembly has a front casting for hinged connection with the vehicle body. Preferably the front casting will be die cast aluminum or titanium to minimize weight. A rear casting is also provided, allowing the door to be latched to the vehicle body. An extrusion or extrusions connect front and rear castings. An optional window frame can be added to further complete the door assembly.

Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a preferred embodiment side door assembly according to the present invention, shown installed in a Jeep-type vehicle;

FIG. 2 is a rear plan view of rear side door assembly shown in FIG. 1;

FIG. 3 is a rear plan view of the front side door assembly shown in FIG. 1;

FIG. 4 is a perspective view of the door assembly shown in FIG. 1 with an alternative hinge pin arrangement;

FIG. 5 is a view similar to that of FIG. 4, illustrating the side door assembly/assemblies shown in FIG. 4 having an additional door panel added thereon;

FIG. 6 is a perspective sectional view illustrating an inner seal utilized for sealing a lower portion of a door assembly according to the present invention;

FIG. 7 is a perspective sectional view of a rear casting of a door assembly according to the present invention illustrating a latch for connection of the door assembly to the vehicle;

FIG. 8 is a door assembly according to the present invention, having a singular lower extrusion connecting front and rear castings;

FIG. 9 is a perspective view of an alternate preferred embodiment side door assembly according to the present invention providing a quarter door;

FIG. 10A is a view of the door assembly according to the present invention providing a half door;

FIG. 10B is a perspective view of the door assembly according to the present invention providing a half door that is netted in a racecar manner;

FIG. 11 is a perspective view of an alternate preferred embodiment door assembly according to the present invention wherein the door extends outwardly;

FIG. 12 is a door assembly similar to that shown in FIG. 11 having an outer door panel;

FIG. 13A is a door assembly similar to that previously described in FIG. 10A having an outer panel;

FIG. 13B is a door similar to that shown in FIG. 13A, additionally having a window frame providing a full door;

FIG. 14 is an exploded view illustrating a method of connection of an extrusion to a casting of the door assembly according to the present invention;

FIG. 15 is an exploded view illustrating an alternate preferred method of connection of an extrusion to a casting of the door assembly according to the present invention;

FIG. 16 is an exploded view illustrating yet another alternate method of connection of extrusion to a casting of the door assembly according to the present invention;

FIG. 17 is a sectioned view illustrating the connection of a portion of the window frame to the remainder of the door assembly of the present invention;

FIG. 18 is a perspective view illustrating the connection of a portion of the window frame to a front of the door assembly casting of the present invention;

FIG. 19 is a perspective view of a window frame of FIG. 18 frame position on its side;

FIG. 20 is a perspective interior view illustrating the window frame of FIG. 18;

FIG. 21 is a side elevational view taken from the interior of the vehicle illustrating a door assembly with an installed outer panel;

FIG. 22 is an enlarged view of the side door assembly shown in FIG. 21 with most of the window frame being removed for clarity of illustration;

FIG. 23 is a perspective view of the door assembly shown in FIG. 22 from the outside of the vehicle;

FIG. 24 is an enlarged perspective view illustrating a portion of a rear casting and extrusion having a recess for acceptance of an outer door panel of FIG. 23;

FIG. 25 is an enlarged perspective view illustrating cam toggles attached to the back side of an outer door panel shown in FIG. 20;

FIG. 26 is a view showing greater detail of the window frame utilized in the door assembly of FIG. 21;

FIG. 27 is an exterior view of a portion of the door assembly illustrating the window frame of the door assembly shown in FIG. 26;

FIG. 28 is an exterior view perspective of an upper window frame casting of the window frame assembly shown in FIG. 26;

FIG. 29 is a sectioned view of the top extrusion frame shown in FIG. 27;

FIG. 30 is a sectioned view illustrating a portion of one of the upright extrusions of the door assembly of FIG. 27;

FIG. 31 is similar to that of FIG. 30 of the other upright extrusion of the window frame;

FIG. 32 is a section illustrating the soft goods attachment method of the window frame shown in FIG. 27;

FIG. 33 is an exploded view similar to that of FIG. 32 illustrating the means of attachment of the frame piece to the lower extrusion of the window frame of the door assembly according to the present inventions;

FIG. 34 is a view taken along line 34-34 of FIG. 3;

FIG. 35 is a view taken along line 35-34 of FIG. 3;

FIG. 36 is a perspective view of a bump-out door assembly of the present invention; and

FIG. 37 is a perspective view of an alternate embodiment of a bump-out door assembly of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.

The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein:

Referring to FIGS. 1 through 3, a side door assembly 7 according to the present invention is provided. The side door assembly 7 is shown utilized to close a side door opening 9 in an automotive vehicle 10. The vehicle 10 shown is a Jeep™ automotive vehicle. As shown, side door assembly 7 is for a rear passenger compartment. Side door assembly 17 illustrates the invention utilized for a front row passenger compartment. Side door assembly 7 has a front casting 10. Casting 10 is typically fabricate from die cast aluminum or titanium. Front casting 10 is provided with upper and lower hinge pins 12 to allow the door 7 to be pivotally connected to the vehicle body 14. Typically the hinge pins are fabricate from stainless steel and are connected to the casting 10 by a press-fit or other suitable attachment method. Door assembly 7 is provided with a rear casting 20. Rear casting 20 is provided with a latch handle 22, which controls a latch mechanism (not shown) to allow the assembly to have a latched connection with vehicle body 14.

A tubular extrusion 26, fabricated from aluminum or titanium, connects front casting 10 to the rear casting 20. It will be readily appreciated that the extrusion is shown as tubular but can be shaped or have other cross-sectional shapes. As shown, door assembly 7 has two additional connective extrusions 28 and 30. Extrusion 28 has an end 32 that is connected with the rear casting 20 at a higher elevation than its frontend 34 with the front casting 10. Lower extrusion 30 has a bend 36 forming a lower portion bordering the side door opening 9. An interior side of lower extrusion 30 and lower portion of the front casting 10 have a channel mounting a sealing bulb to seal the bottom portion door assembly 7 with the door opening 9. FIG. 2 is a view of the door assembly shown in FIG. 1 from the interior of the vehicle. In FIG. 2 an outer skin 40 has been added. The upper extrusion 36 and the middle extrusion 28 have a T-slot feature (see FIGS. 34 and 35) for attachment of add-on accessories. Lower extrusion 30 also has the T-slot. A cable operated by latch handle 44 (FIG. 1) can extend through an interior of the top extrusion 26 to operate a two-stage rotary latch with anti-rattle overmold 42. Referring back to FIG. 1, latch handle 44 is a Jeep TJ-style panel latch and is at the same elevation as latch handle 22 for styling purposes. Door assembly 17 is constructed in a manner similar to that of door assembly 17, however door assembly 17 additionally has a tower 46 to allow for attachment of the rear view mirror and associated hardware.

Referring to FIG. 14, various attachment methods are illustrated. In FIG. 14 an extrusion 50 has an aperture 52 allowing it to be boltably connected to a casting 54 by a fastener with a front or rear end of the extrusion being placed within a pocket 56 provided in the casting with a matching fastener hole 58. Typically the fastener is connected from the inside to prevent it showing on the exterior of the vehicle. In FIG. 15 an extrusion 60 has a female opening fitted over a male stud 64 of a casting 66. In FIG. 16 an extrusion 68 is abuttingly connected with a casting 70 by bolts extending through extrusion 68 transverse to its longitudinal axis 72.

FIGS. 5 and 4 illustrate the door assemblies 7 and 17 with alternative hinge pin arrangement 73. The hinge pin arrangement 73 is typically utilized in external hinge pin arrangements. Additionally, in FIG. 5, the door assemblies 7 and 17 are shown with an exterior door panel 40 and 43.

FIG. 6 illustrates a bottom portion of a lower extrusion 76 having a recess 77 for acceptance of an outer panel 78. The panel 78 is partially sealed by a preform or applied sealant 79. The sealant and panel 78 are fitted in the recess 77. The extrusion 76 also has an open groove 81 having generally perpendicular wall 83 (as shown horizontally) and 85 (shown vertically) that adhesively connect a sealing bulb or weather strip 80 to seal a lower portion of the door opening.

FIG. 7 illustrates a rear casting 86 mounting latched hardware 88 for engagement with a striker 90 connected with the vehicle body 14.

FIG. 8 illustrates a door assembly 107 having a front casting 120 and a rear casting 122 joined only by a lower extrusion 130.

FIG. 9 illustrates a door assembly 127 having a front casting 120 and a rear casting 122 connected by an upper extrusion 125 and a midpoint extrusion 129 forming a quarter door.

FIG. 10A illustrates door assembly 131, essentially identical to door assembly 172 with an addition of a lower extrusion 130A. The door assembly 131 is typically referred to as a half-door assembly. The half door in FIG. 10B illustrates the door 131A with the addition of a racing net. FIG. 13A illustrates the door assembly 131 with the addition of an outer door panel. Typically, the outer panel is an aluminum stamping, vacuum-formed plastic or durable fabric. Door assembly 131 in FIGS. 10A and 10B, and in 13A are commonly referred to as half doors. FIG. 13B is essentially identical to the door assembly 131, however 13A additionally has an added window frame 134 and is commonly referred to as a full door.

FIG. 11 provides a door assembly 147 of a half door with front and rear castings 120 and 122. Door assembly 147 has an upper extrusion 151 that is arcuately bent outboard extending away from the vehicle body. Extrusion 151 is joined by two generally vertically inclined extrusions 153 that connect with the lower extrusion 130. FIG. 12 illustrates the door assembly as shown in FIG. 11 covered with an outer panel of material similar to that as noted in the door assembly described in 13A and 13B.

Referring to FIGS. 17 through 21, a door assembly 207 is provided having a connected window frame 209. Window frame 209 is fabricated from an upper rear casting 210, an upper front casting 214, a lower rear casting 216 and a lower front casting 218. Typically the fabrication material will be the same as for the door casting as previously described. The lower rear casting 216 and the front door casting 218 both have mounting blades 220. The lower castings 216 and 218 are connected with a lower extrusion 222. Castings 214 and 210 are connected by an upper extrusion 224. Castings 214 and 218 are joined by an extrusion 226, and castings 210 and 216 are connected by an extrusion 228. The rear window frame casting blade 220 extends into an aperture 230 formed on a generally flat horizontal portion 232 of a rear casting 236 of the door assembly. The blade 220 juxtaposes elastomeric inserts 238 and 240. Typically the longitudinal length of the elastomeric inserts 238 and 240 will be slightly larger than that of blade 220. Insert 238 has a generally vertical portion 240 joining to a generally horizontal portion 242. Horizontal portion 242 has a generally inclined top surface 244. Opposite elastomeric insert 240 has a generally vertical portion 250 joining to a horizontal portion 252. Horizontal portion 252 has a generally horizontal surface 254 blending into arcuate declining surface 256 and a vertical surface 258. An elastomeric strap 260 I provided for pulling down the door frame to the remainder of the door assembly. A horizontal surface 262 of the window casting 216 abuts the flat portion 242 of the door casting 236. Window casting 216 has an arcuate curvilinear edge 264 having mating contact with a downward incline curvilinear edge portion 270 of the door assembly rear casting 236. The blade 220 of window front casting 218 also fits an aperture of a front casting 272 of the door assembly. However, it is at a higher elevation than the blade 220 of the rear window casting. The details of elastomeric inserts of the front lower casting 218 of the window are essentially identical to those previously described.

FIGS. 28 through 33 illustrate further detail of the window frame 209. Referring in particular to FIG. 28, window casting 214 has a first male member 276, including a main male member 280 and a stud male member 282. A second male member 284 is also provided and a T-shaped cross sectional third male member 286 is also provided. Male member 286 has an aperture 288 to allow for connection of extrusion 224 to the casting 214 trim piece (sometimes referred to as a trim ring), which has an aperture 290 to allow for its bolted connection to the extrusion 224. The extrusion 224 has a channel 292 for reception of the male member 286 and the corresponding male member of window frame casting 210. Extrusion 224 also has a channel 294 for acceptance of an arrowhead extrusion utilized in maintaining the soft goods attachment of a twill carrier. Extrusion 224 has another channel 296, generally triangular in shape, for reception of male member 284 and for providing a surface for connection of the trim piece 267. Extrusion 224 also has a fourth channel 298. Channel 298 accepts male member 276 and supports a sealing bulb 300 that compressively loads and seals the window frame of the vehicle door opening. Seal 330 is typically adhesively connected with the channel 298.

The method of soft goods attachment is for lower extrusion 222 to have a first step 302 for support of the trim piece 267 and a higher step 304 supporting an arrowhead-type extrusion 306, which is sewn to a trill carrier arrowhead extension 306, fitted within a channel 308 similar to the channel 294 previously described.

Referring additionally to FIGS. 22 through 25, door assembly 207 is provided with an outer panel 312. Outer panel 312 is connected to front and rear door castings by a series of toggle switches 320. Toggle switches also connect the outer panel 312 to upper and lower extrusions. The extrusions and the front and rear castings have a recess 340 allowing the door panel to have a seamless look.

The door assembly 207 has a series of door hinges 350 that are symmetrical and can be used in the front and rear inside and outside, or left and right side of a vehicle utilizing the same.

Referring now to FIGS. 36 and 37, there is shown a half door assembly which includes a portion 302 that extends outward from the door framework 300 of a vehicle. As shown in these figures a door frame portion 300 is hingedly attached to the vehicle 310. The door framework portion substantially fits within the door opening of the vehicle and substantially matches the planar vertical and horizontal planar surfaces of the vehicle 310. The side structure 302 extend outwardly form the vehicle to form a three dimensional shape which extends outwardly from the planar surface of the vehicle 310.

As shown in FIG. 36 the structure 302 can be bolted or welded to the framework 300 of the door. A panel such as 304 can be bolted to the framework or otherwise attached such as by welding if desired. Panels 302a and 302b also form a three-dimensional structure outside the planar surface of the vehicle and are attached either to the door framework or to the portion 302 depending on the desired final construction.

In the embodiment shown in FIG. 36 the bump out portion slopes outward from the bottom 306 to the top 308 as shown in the drawings.

The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. 

What is claimed is:
 1. A side door assembly for an automotive vehicle body having a side opening, said assembly comprising: a front casting for hinged connection to the vehicle body; a rear casting latch connection vehicle body; and an extrusion connecting said front and rear casting.
 2. The door assembly described in claim 1 wherein said castings are fabricated from a group of materials including aluminum and titanium.
 3. The door assembly of claim 1 wherein said extrusion is a tubular member fabricated from a group of materials including aluminum and titanium.
 4. The door assembly of claim 1 wherein said door is a quarter door.
 5. The door assembly of claim 1 wherein said door is a half door.
 6. The door assembly of claim wherein said door is a full door.
 7. The door assembly of claim 1 having two extrusions connecting said castings.
 8. The door assembly of claim 1 having three extrusions connecting said castings.
 9. The door assembly of claim 1 wherein said front casting also mounts a rear view mirror.
 10. The door assembly of claim 1 wherein said front casting has a pressed-in stainless steel pivot pin.
 11. The door assembly of claim 1 wherein an extrusion provides a curved border portion of said door opening.
 12. The door assembly of claim 1 wherein said extrusion and said casting mount a sealing bulb for a lower portion of the door opening.
 13. The door assembly of claim 1 wherein said extrusion is connected with said casting by at least one of the methods taken from a group of placement of said extrusion in a pocket provided within said casting in combination with a fastener, a female opening of said extrusion receiving a male stud of said casting in combination with a fastener, and a fastener connecting said extrusion with said casting in abutting contact with said casting transverse to the axis of extension of said extrusion.
 14. The door assembly of claim 1 wherein the castings are connected by a lower extrusion and an upper extrusion and said upper extrusion bows outboard from said lower extrusion.
 15. The door assembly of claim 14 further including vertically extending extrusions joining said upper and lower extrusions that connect with said castings.
 16. The door assembly of claim 1 having upper lower and middle extrusions connecting said castings and wherein said middle extrusion connects with said rear casting and elevation higher in its connection with the front casting.
 17. The door assembly of claim 1 having upper and lower extrusions connecting said castings and wherein said lower connection with said rear casting is at a higher elevation than said lower extrusion connecting with said front casting. (FIG. 4)
 18. The door assembly of claim 1 wherein said door latch is a Jeep TJ paddle latch.
 19. The door assembly of claim 1 wherein operating cable for said door latch is routed inside said tubular extension.
 20. The door assembly of claim 1 further including a window frame connected to said door assembly by a blade connected with said window frame inserted within an aperture of said casting, said blade juxtaposing elastomeric inserts inserted within said aperture.
 21. The door assembly of claim 20 wherein said inserts have a portion extending along a generally horizontal plane joining to a portion extending in a generally vertical plane.
 22. The door assembly of claim 21 wherein said window frame has a portion in vertical abutting contact with said casting and another portion with angular contact with an angled portion of said casting.
 23. The door assembly of claim 22 wherein said casting has a horizontal portion with said aperture joining to an arcuate curvilinear portion connected with said horizontal portion curving generally downward and wherein said window frame abutting vertical contact is with said horizontal portion and said window frame angular contact is with said casting curvilinear portion.
 24. The door assembly of claim 23 wherein said curvilinear portion of said casting is adjacent an outer portion of said door assembly.
 25. The door assembly of claim 20 wherein said window frame is connected to said castings by a rubber latch.
 26. The door assembly of claim 20 wherein said window frame has two blades for insertion into apertures, said front and rear castings and said apertures are at different elevations.
 27. The door assembly of claim 1 wherein a window frame of said door assembly is fabricated from at least two spaced apart castings and wherein said castings are joined by a tubular extrusion.
 28. The door assembly of claim 27 wherein said window includes a channel for mounting an arrowhead extrusion and a channel for mounting a trim piece and a channel for supporting a ceiling ring with the door opening and a channel providing a female opening for a casting male member.
 29. The door assembly of claim 28 wherein said channel for supporting said ceiling ring and said channel for supporting said trim piece also, except male members of said casting.
 30. The door assembly of claim 26 wherein said window frame has front, upper and lower castings connected to each other by upper, lower, front and rear tubular extrusions.
 31. The door assembly of claim 27 wherein said window includes a channel for mounting an arrowhead extrusion and a channel for mounting a trim piece, and said channel for mounting said trim piece has a step for supporting a soft good retain to said extrusion by said arrowhead extrusion and a second step for supporting said trim piece wherein said trim piece conceals said soft good connection with said arrowhead extrusion from view.
 32. The door assembly of claim 1 wherein an outer door panel is connected with said casting and said extrusion by cam toggles.
 33. The door assembly of claim 32 wherein said castings and extrusions have a recess for acceptance of said outer door panel.
 34. The door assembly of claim 32 wherein said extrusion includes a T-slot to allow an attachment feature for connection of accessories.
 35. The door assembly of claim 32 wherein said outer door panel can be removed without removal of a latch, latch handle or mirror connected with said door assembly.
 36. The door assembly of claim 1 wherein said front casting has a mirror mount that can accept Jeep TJ or Jeep JK-style mirrors.
 37. The door assembly of claim 1 with common bolt-on door hinges, said hinges being universal for all side doors of said vehicle.
 38. A half door for a vehicle comprising: a half door framework including hinges for hingedly attaching the door to a vehicle substantially and fitting within the door frame of the vehicle having an outer surface matching a substantially vertical planar side portion of a vehicle; and a side structure extending from said frame for forming a three-dimensional structure on said half door extending outwardly from said vertical planar side portion of the vehicle.
 39. The half door for a vehicle of claim 38 wherein said half door includes a top and a bottom and said three-dimensional surface is sloped outward of the vehicle from the bottom to the top.
 40. The half door for a vehicle of claim 39 wherein said side structure is interchangeably attached to said half door for providing another three-dimensional contoured surface to said half door. 